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Abstract:

The present invention relates to a polymer composition containing the
following components: a) 30-97 mass % of aromatic polycarbonate, b)
0.5-20 mass % of a metal compound capable of being activated by
electromagnetic radiation and thereby forming elemental metal nuclei, and
c) 2.5-50 mass % of at least one rubber-like polymer, wherein the sum of
a)-c) is 100%.

Claims:

1. Polymer composition containing the following components: a) 30-97 mass
% of aromatic polycarbonate, b) 0.5-20 mass % of a metal compound capable
of being activated by electromagnetic radiation and thereby forming
elemental metal nuclei, and c) 2.5-50 mass % of at least one rubber-like
polymer, wherein the sum of a)-c) is 100%.

2. Polymer composition according to claim 1, wherein component b) is a
metal oxide having a spinel structure.

4. Polymer composition according to claim 1, wherein the composition
contains, as rubber like polymer, an elastomeric polymer.

5. Polymer composition according to claim 1, wherein the composition
contains, as rubber like polymer, a graft copolymer containing an
elastomeric polymer.

6. Polymer composition according to claim 5, wherein the graft copolymer
containing an elastomeric polymer is a graft copolymer prepared by
polymerizing 5 to 90 parts by weight, based on the graft copolymer, of
one or more monomers in the presence of 95 to 10 parts by weight, based
on the graft copolymer, of particles of the elastomeric polymer.

7. Polymer composition according to claim 1, wherein the elastomeric
polymer is a butadiene based rubber, an acrylate based rubber or a
siloxane based rubber.

8. Polymer composition according to claim 1, wherein component c) is a
butadiene based rubber, an acrylate based rubber or a siloxane based
rubber.

9. Polymer composition according to claim 1, wherein component c) is at
least one graft copolymer prepared by polymerizing 5 to 90 parts by
weight, based on c), of one or more monomers in the presence of 95 to 10
parts by weight, based on c), of particles of an elastomeric polymer.

11. Moulded part that contains the polycarbonate composition according to
claim 1.

12. A circuit carrier that contains at least a moulded part according to
claim 11.

13. A process for producing a circuit carrier according to claim 12
comprising the steps of providing a moulded part, irradiating areas of
said part on which conductive tracks are to be formed with
electromagnetic radiation to break down the metal compound b) and
releasing metal nuclei, and subsequently metallizing the irradiated
areas.

14. Process for reducing degradation of aromatic polycarbonate in an
aromatic polycarbonate composition also containing a metal compound b)
capable of being activated by electromagnetic radiation and thereby
forming elemental metal nuclei, characterized in that the process further
comprises mixing said composition with at least one rubber-like polymer
to obtain an aromatic polycarbonate composition with increased melt
stability.

15. Process according to claim 14, characterized in that the melt stable
aromatic polycarbonate composition contains a) 30-97 mass % of aromatic
polycarbonate, b) 0.5-20 mass % of a metal compound capable of being
activated by electromagnetic radiation and thereby forming elemental
metal nuclei, and c) 2.5-50 mass % of at least one rubber-like polymer,
wherein the sum of a)-c) is 100%.

16. Process according to claim 15, wherein component b) is a metal oxide
having a spinel structure.

18. Process according to claim 15, wherein the rubber-like polymer is
acrylonitrile butadiene styrene (ABS) or a siloxane based rubber.

Description:

[0001] The invention relates to a polymer composition comprising a
polymer, in particular an aromatic polycarbonate, and a metal compound
capable of being activated by electromagnetic radiation and thereby
forming elemental metal nuclei. The invention also relates to a process
for producing such a composition, to a moulded part containing this
composition, to a circuit carrier containing such moulded part and to a
process for producing such circuit carrier.

[0002] Polymer compositions comprising a polymer and a metal compound
capable of being activated by electromagnetic radiation and thereby
forming elemental metal nuclei are for example described in U.S. Pat. No.
7,083,848 and U.S. Pat. No. 7,060,421. Such polymer compositions can
advantageously be used for producing a non-conductive part on which
conductive tracks are to be formed by irradiating areas of said part with
electromagnetic radiation to break down the metal compound(s) and release
metal nuclei, and subsequently metallizing the irradiated areas to
accumulate metal on these areas.

[0003] Applicant has found now that the presence of such metal compounds
in aromatic polycarbonate compositions results in degradation of the
polycarbonate resulting in a decrease of the melt stability of the
compositions and thus in less stable processing.

[0004] The object of the invention is to provide a polycarbonate
composition, comprising a metal compound capable of being activated by
electromagnetic radiation and thereby forming elemental metal nuclei,
that does not show said drawback or shows it to a lesser extent.

[0005] This object is achieved in that the polymer composition contains
the following components: [0006] a) 30-97 mass % of aromatic
polycarbonate, [0007] b) 0.5-20 mass % of a metal compound capable of
being activated by electromagnetic radiation and thereby forming
elemental metal nuclei, and [0008] c) 2.5-50 mass % of at least one
rubber like polymer, wherein the sum of a)-c) is 100%.

[0009] It has surprisingly been found that the degradation of the aromatic
polycarbonate in the polymer composition according to the present
invention is decreased or even prevented, as for example manifested in an
increase of melt flow stability and/or toughness. As used herein,
degradation of polycarbonate refers to a reduction in molecular weight.

[0010] The present invention therefore also relates to a process for
reducing degradation of the aromatic polycarbonate in an aromatic
polycarbonate composition also containing a metal compound b) capable of
being activated by electromagnetic radiation and thereby forming
elemental metal nuclei, by mixing said composition with at least one
rubber like polymer to obtain a polymer composition containing the
following components a) 30-97 mass % of aromatic polycarbonate, b) 0.5-20
mass % of a metal compound capable of being activated by electromagnetic
radiation and thereby forming elemental metal nuclei, and c) 2.5-50 mass
% of at least one rubber like polymer, wherein the sum of a)-c) is 100%.
In a preferred embodiment, the polymer composition contains a) 30-95 mass
% of aromatic polycarbonate, b) 0.5-20 mass % of a metal compound capable
of being activated by electromagnetic radiation and thereby forming
elemental metal nuclei, and c) 4.5-50 mass % of at least one rubber like
polymer, wherein the sum of a)-c) is 100%.

[0011] The polycarbonate composition according to the invention contains
inter alia from 30 up to 97 mass % of aromatic polycarbonate, preferably
from 30 up to 96 mass %, preferably from 30 up to 95 mass %, more
preferably from 15 up to 90 mass % of aromatic polycarbonate, even more
preferably from 50 up to 85 mass % of aromatic polycarbonate. Suitable
aromatic polycarbonates are polycarbonates made from at least a divalent
phenol and a carbonate precursor, for example by means of the commonly
known interfacial polymerization process or the melt polymerisation
method. Suitable divalent phenols that may be applied are compounds
having one or more aromatic rings that contain two hydroxy groups, each
of which is directly linked to a carbon atom forming part of an aromatic
ring. Examples of such compounds are [0012] 4,4'-dihydroxybiphenyl,
2,2-bis(4-hydroxyphenyl)propane (bisphenol A), [0013]
2,2-bis(4-hydroxy-3-methylphenyl)propane, [0014]
2,2-bis-(3-chloro-4-hydroxyphenyl)-propane, [0015]
2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, [0016]
2,4-bis-(4-hydroxyphenyl)-2-methylbutane, [0017]
2,4-bis-(3,5-dimethyl-4-hydroxyphenyl)-2-methylbutane, [0018]
4,4-bis(4-hydroxyphenyl)heptane,
bis-(3,5-dimethyl-4-hydroxyphenyl)-methane, [0019]
1,1-bis-(4-hydroxyphenyl)-cyclohexane, [0020]
1,1-bis-(3,5-dimethyl-4-hydroxyphenyl)-cyclohexane, [0021]
2,2-(3,5,3',5'-tetrachloro-4,4'-dihydroxydiphenyl)propane, [0022]
2,2-(3,5,3',5'-tetrabromo-4,4'-dihydroxydiphenyl)propane, [0023]
(3,3'-dichloro-4,4'-dihydroxyphenyl)methane, [0024]
bis-(3,5-dimethyl-4-hydroxyphenyl)-sulphon, bis-4-hydroxyphenylsulphon,
[0025] bis-4-hydroxyphenylsulphide.

[0026] The carbonate precursor may be a carbonyl halogenide, a halogen
formate or carbonate ester. Examples of carbonyl halogenides are carbonyl
chloride and carbonyl bromide. Examples of suitable halogen formates are
bis-halogen formates of divalent phenols such as hydroquinone or of
glycols such as ethylene glycol. Examples of suitable carbonate esters
are diphenyl carbonate, di(chlorophenyl)carbonate,
di(bromophenyl)carbonate, di(alkylphenyl)carbonate, phenyltolylcarbonate
and the like and mixtures thereof. Although other carbonate precursors
may also be used, it is preferred to use the carbonyl halogenides and in
particular carbonyl chloride, also known as phosgene.

[0027] The aromatic polycarbonates in the composition according to the
invention may be prepared using a catalyst, an acid acceptor and a
compound for controlling the molecular mass.

[0028] Examples of catalysts are tertiary amines such as triethylamine,
tripropylamine and N,N-dimethylaniline, quaternary ammonium compounds
such as tetraethylammoniumbromide and quaternary phosphonium compounds
such as methyltriphenylfosfoniumbromide.

[0029] Examples of organic acid acceptors are pyridine, triethylamine,
dimethylaniline and so forth. Examples of inorganic acid acceptors are
hydroxides, carbonates, bicarbonates and phosphates of an alkali metal or
earth alkali metal.

[0030] Examples of compounds for controlling the molecular mass are
monovalent phenols such as phenol, p-alkylphenols and para-bromophenol
and secondary amines.

[0031] Such polycarbonates, their preparation and properties are described
in detail in for example Encycl. Polym. Sci. Eng., 11, p. 648-718 (Wiley,
New York, 1988) and in Kunststoff Handbuch, 3/1, p. 117-297 (Hanser
Verlag, Muenchen, 1992).

[0032] The composition according to the invention preferably contains a
polycarbonate derived from bisphenol A and phosgene and optionally minor
amounts of other compounds having one, two or more than two reactive
groups as comonomers, for instance for controlling the melt viscosity.

[0033] The component b) capable of being activated by radiation is a
metal-containing (inorganic or organic) compound which as a consequence
of absorption of electromagnetic radiation liberates metal in elemental
form, in a chemical reaction. It is also possible that the
electromagnetic radiation is not directly absorbed by the
metal-containing compound, but is absorbed by other substances which then
transfer the absorbed energy to the metal-containing compound and thus
bring about the liberation of elemental metal. The electromagnetic
radiation may be UV light (wavelength from 100 to 400 nm), visible light
(wavelength from 400 to 800 nm), or infrared light (wavelength from 800
to 25 000 nm). Other preferred forms of radiation are X-rays, gamma rays,
and particle beams (electron beams, [alpha]-particle beams, and
[beta]-particle beams).

[0034] The metal compound b) is capable of being activated by
electromagnetic radiation and thereby forming elemental metal nuclei
within the polycarbonate composition. The component b) capable of being
activated by radiation is comprised of electrically non-conductive
high-thermal-stability organic or inorganic metal compounds which are
preferably insoluble and stable in aqueous acidic or alkaline metalizing
baths. Particularly suitable compounds are those which absorb a very
large proportion of the light at the wavelength of the incident light.
Compounds of this type are described in EP-A-1 274 288. Preference is
given here to compounds of metals of the d and f group of the Periodic
Table of the Elements with non-metals. The metal-containing compounds are
particularly preferably metal oxides, in particular oxides of the
d-metals of the Periodic Table of the Elements. Higher metal oxides which
contain at least two different kinds of cations and have a spinel
structure or spinel-related structure, and which remain unchanged in
non-irradiated areas of the moulded part that contains the composition of
the present invention are particularly suitable. In one particularly
preferred embodiment of the invention, the higher oxides are spinels, in
particular copper-containing spinels, such as CuCr2O4. Suitable
copper-containing spinels are commercially available, an example being PK
3095 from Ferro (DE) or 34E23 or 34E30 from Johnson Matthey (DE). Copper
oxides of the formula CuO or Cu20 are also particularly suitable,
and use is preferably made here of nanoparticles, such as NANOARC®
Copper Oxide from Nanophase Technologies Corporation, Illinois, USA. In
another particularly preferred embodiment of the invention, the higher
spinel oxide is a manganese-containing spinel. As will be understood by a
man skilled in the art also a mixture of metal compounds having a spinel
structure can be used.

[0035] Preferably, the metal compound is represented by the chemical
formula AB2O4 or B(AB)O4. The A component of the formulas
is a metal cation having a valence of 2 and is selected from the group
consisting of cadmium, zinc, copper, cobalt, magnesium, tin, titanium,
iron, aluminum, nickel, manganese, chromium, and combinations of two or
more of these. The B component of the formulas is a metal cation having a
valence of 3 and is selected from the group consisting of cadmium,
manganese, nickel, zinc, copper, cobalt, magnesium, tin, titanium, iron,
aluminum, chromium, and combinations of two or more of these.

[0036] The polymer compositions of the invention have dispersed therein
metal compound(s), where the metal compound preferably comprises two or
more metal oxide cluster configurations within a definable crystal
formation. The overall crystal formation, when in an ideal (i.e.,
non-contaminated, non-derivative) state, has the following general
formula:

AB2O4, where

i. A is selected from the group consisting of cadmium, zinc, copper,
cobalt, magnesium, tin, titanium, iron, aluminum, nickel, manganese,
chromium, and combinations thereof, which provides the primary cation
component of a first metal oxide cluster ("metal oxide cluster 1")
typically a tetrahedral structure, ii. B is selected f from the group
consisting of cadmium, manganese, nickel, zinc, copper, cobalt,
magnesium, tin, titanium, iron, aluminum, chromium, and combinations
thereof and which provides the primary cation component of a second metal
oxide cluster ("metal oxide cluster 2") typically an octahedral
structure, iii. where within the above groups A or B, any metal cation
having a possible valence of 2 can be used as an "A", and any metal
cation having a possible valence of 3 can be used as a "B", iv. where the
geometric configuration of "metal oxide cluster 1" (typically a
tetrahedral structure) is different from the geometric configuration of
"metal oxide cluster 2" (typically an octahedral structure), v. where a
metal cation from A and B can be used as the metal cation of "metal oxide
cluster 2" (typically the octahedral structure), as in the case of an
`inverse` spinel-type crystal structure, vi. where O is primarily, if not
exclusively, oxygen; and vii. where the "metal oxide cluster 1" and
"metal oxide cluster 2" together provide a singular identifiable crystal
type structure having heightened susceptibility to electromagnetic
radiation.

[0037] The concentration of these components b) present in the composition
of the present invention is from 0.5 up to 20 mass %, preferably from 1
up to 20 mass %, preferably from 3 up to 10 mass %, more preferably from
4 up to 10 mass %, and particularly preferably from 5 up to 10 mass %.

[0038] It has surprisingly been found that the presence of a rubber like
polymer in an amount of at least 2.5 mass % in aromatic polycarbonate
compositions comprising a metal compound capable of being activated by
electromagnetic radiation and thereby forming elemental metal nuclei,
results in less degradation or even prevents the degradation of the
polycarbonate in the composition, as for example manifested in an
increase of melt flow stability and/or toughness. Component c) in the
composition of the present invention is at least one rubber like polymer.
The rubber-like polymer is or contains an elastomeric (i.e. rubbery)
polymer having preferably a Tg less than about 10° C., more
specifically less than about -10° C., or more specifically about
-20° C. to -80° C. Examples of elastomeric polymers include
polyisoprene; butadiene based rubbers like polybutadiene,
styrene-butadiene random copolymer and block copolymer, hydrogenates of
said block copolymers, acrylonitrile-butadiene copolymer and
butadiene-isoprene copolymer; acrylate based rubbers like
ethylene-methacrylate and ethylene-butylacrylate, acrylate
ester-butadiene copolymers, for example acrylic elastomeric polymers such
as butylacrylate-butadiene copolymer; siloxane based rubbers like
polyorganosiloxanes such as for example polydimethylsiloxane,
polymethylphenylsiloxane and dimethyl-diphenylsiloxane copolymer; and
other elastomeric polymers like ethylene-propylene random copolymer and
block copolymer, copolymers of ethylene and α-olefins, copolymers
of ethylene and aliphatic vinyl such as ethylene-vinyl acetate, and
ethylene-propylene non-conjugated diene terpolymers such as
ethylene-propylene-hexadiene copolymer, butylene-isoprene copolymer, and
chlorinated polyethylene, and these substances may be used individually
or in combinations of two or more. Preferred elastomeric polymers
include, for example, conjugated diene rubbers; copolymers of a
conjugated diene with less than about 50 wt. % of a copolymerizable
monomer; olefin rubbers such as ethylene propylene copolymers (EPR) or
ethylene-propylene-diene monomer rubbers (EPDM); ethylene-vinyl acetate
rubbers; siloxane rubbers; elastomeric C1-C8 alkyl
(meth)acrylates; elastomeric copolymers of C1-8 alkyl
(meth)acrylates with butadiene and/or styrene; or combinations comprising
at least one of the foregoing elastomers. More preferred elastomeric
polymers are butadiene based rubbers, acrylate based rubbers and siloxane
based rubbers. Particularly preferred elastomeric polymers are siloxane
rubbers and butadiene based rubbers, with polybutadiene,
styrene-butadiene random copolymer and block copolymer, hydrogenates of
said block copolymers being particularly preferred. In one preferred
embodiment, the composition according to the invention contains at least
a butadiene based rubber as component c). In another preferred
embodiment, the composition according to the invention contains at least
a siloxane based rubber as component c).

[0039] In one embodiment of the present invention, the composition
according to the invention contains an elastomeric polymer as at least
one of the rubber like polymers. Non-limiting examples of elastomeric
polymers and preferred elastomeric polymers are listed above. In a
preferred embodiment, the composition contains a butadiene based rubber,
an acrylate based rubber or a siloxane based rubber as rubber like
polymer. Non-limiting examples of butadiene based rubbers, acrylate based
rubbers or siloxane based rubbers are described above. Particularly
preferred rubber like polymers are siloxane rubbers and butadiene based
rubbers, with polybutadiene, styrene-butadiene random copolymer and block
copolymer, hydrogenates of said block copolymers being particularly
preferred.

[0040] In another and more preferred embodiment of the present invention,
the composition according to the invention contains, as at least one of
the rubber like polymers, a component containing an elastomeric polymer
as described above. The component containing an elastomeric polymer is
preferably a graft copolymer containing an elastomeric polymer. More
preferably, the component containing an elastomeric polymer is obtained
by grafting the elastomeric polymer with a rigid polymeric superstrate.
As is known, elastomer-modified graft copolymers may be prepared by first
providing the elastomeric polymer, then polymerizing the constituent
monomer(s) of the rigid phase in the presence of the elastomer to obtain
the graft copolymer. The grafts may be attached as graft branches or as
shells to an elastomer core. The shell may merely physically encapsulate
the core, or the shell may be partially or essentially completely grafted
to the core. The rubber like polymer(s) present in the composition of the
present invention is thus an optionally grafted elastomeric polymer. In
case the elastomeric polymer is grafted, the grafted elastomeric polymer
is preferably a graft copolymer obtained by grafting the elastomeric
polymer with a rigid polymeric superstrate. The graft copolymer is
preferably a graft copolymer prepared by polymerizing 5 to 90 parts by
weight, based on the graft copolymer, of one or more monomers in the
presence of 95 to 10 parts by weight, based on the graft copolymer, of
particles of the elastomeric polymer.

[0041] Preferred components c) are graft copolymers prepared by
polymerizing 5 to 90 parts by weight, based on c), of one or more
monomers in the presence of 95 to 10 parts by weight, based on c),
particles of the elastomeric polymer because the use of the monomer(s)
results in an increased compatibility between the rubber like polymer and
the polycarbonate matrix and hence results in that component c) is more
uniformly dispersed in the polycarbonate matrix to further decrease the
degradation of the aromatic polycarbonate in an aromatic polycarbonate
composition also containing a metal compound b) capable of being
activated by electromagnetic radiation and thereby forming elemental
nuclei.

[0042] In case the elastomeric polymer is a siloxane based rubber,
component c) is preferably a polyorganosiloxane containing graft
copolymer preferably prepared by polymerizing 5 to 60 parts by weight of
a vinyl monomer (c-I) in the presence of 40 to 95 parts by weight of
polyorganosiloxanes particles (c-II) (the sum of (c-I) and (c-II) is 100
parts by weight), as for example described in US2005/0143520. Examples of
the vinyl monomers (c-I) include, for example, aromatic vinyl monomers
such as styrene, alpha-methylstyrene, p-methylstyrene, and
p-butylstyrene; vinylcyanide monomers such as acrylonitrile and
methacrylonitrile; (meth)acrylic acid ester monomers such as methyl
acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, 2-ethylhexyl
acrylate, glycidyl acrylate, hydroxyethyl acrylate, hydroxybutyl
acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate,
lauryl methacrylate, glycidyl methacrylate, and hydroxyethyl
methacrylate; and carboxyl-group-containing vinyl monomers such as
itaconic acid, (meth)acrylic acid, fumaric acid, and maleic acid. The
vinyl monomer (c-I) may include a multifunctional monomer having at least
two polymerizable unsaturated bonds per molecule, if necessary. Examples
of the multifunctional monomers include allyl methacrylate, triallyl
cyanurate, triallyl isocyanurate, diallyl phthalate, ethylene glycol
dimethacrylate, 1,3-butylene glycol dimethacrylate, and divinylbenzene.
The vinyl monomer (c-I) may be used alone or in combination. The
polyorganosiloxane particles (c-II) are preferably prepared by emulsion
polymerization of the constituent components. A normal seeded emulsion
polymerization can be applied to the graft copolymerization and can be
achieved by radical-polymerizing the vinyl monomer (c-I) in latex of the
polyorganosiloxane particles (c-II).

[0043] In a preferred embodiment of the invention, component c) is one or
more graft copolymer of

c.1.) 5 to 90 parts by weight, preferably 20 to 90 parts by weight, based
on c), of a mixture of c.1.1) 50 to 95% by weight styrene, α-methyl
styrene, nucleus-substituted styrene, methyl methacrylate or mixtures
thereof, and c.1.2) 50 to 5% by weight (meth)acrylonitrile, methyl
methacrylate, n-butyl acrylate, t-butyl (meth)acrylate or mixtures
thereof, on c.2) 95 to 10 parts by weight, preferably 80 to 10 parts by
weight, based on c), of an elastomeric polymer selected from a butadiene
based rubber, a rubber of ethylene, propylene and an unconjugated diene,
and an acrylate based rubber. Preferably c.2) being a butadiene based
rubber. Examples of suitable butadiene based rubbers, rubbers of
ethylene, propylene and an unconjugated diene and acrylate based rubbers
are given above. Useful graft copolymers are for example described in
EP-A-1007593 and U.S. Pat. No. 5,061,745. Particularly preferred graft
copolymers are ABS resin (acrylonitrile-butadiene-styrene copolymer), AES
resin (acrylonitrile-ethylene-propylene-styrene copolymer), AAS resin
(acrylonitrile-acrylic elastomer-styrene copolymer), and MBS (methyl
methacrylate butadiene styrene copolymer). Particularly preferred graft
copolymers are acrylonitrile butadiene styrene rubber (ABS),
methylmethacrylate butadiene styrene rubber (MBS) or a mixture of these
copolymers, because of the high compatibility between the polycarbonate
matrix and such copolymers, thereby enabling that these copolymers can be
uniformly dispersed into the polycarbonate matrix to further decrease the
degradation of the aromatic polycarbonate in an aromatic polycarbonate
composition also containing a metal compound b) capable of being
activated by electromagnetic radiation and thereby forming elemental
nuclei. From an economic point of view is acrylonitrile butadiene styrene
(ABS) even more preferred. Any commercially available ABS may be applied.
Particularly preferred acrylonitrile butadiene styrene (ABS) is
acrylonitrile butadiene styrene a rubber content of 10 to 50 parts by
weight, preferably 10 to 40 parts by weight and even more preferably 10
to 30 parts by weight.

[0044] In one preferred embodiment of the invention, the composition
comprises an aromatic polycarbonate, a metal compound b), a siloxane
based rubber or a siloxane based rubber containing graft copolymer as
rubber-like polymer, wherein the siloxane based rubber or the siloxane
based rubber containing graft copolymer is added to reduce the
degradation of the aromatic polycarbonate in an aromatic polycarbonate
composition also containing a metal compound b). In this embodiment the
rubber-like polymer is preferably a polyorganosiloxane containing graft
copolymer preferably prepared by polymerizing 5 to 60 parts by weight of
a vinyl monomer (c-I) in the presence of 40 to 95 parts by weight of
polyorganosiloxanes particles (c-II) (the sum of (c-I) and (c-II) is 100
parts by weight), as for example described in US2005/0143520. Examples of
the vinyl monomers (c-I) are described above. In another preferred
embodiment of the invention, the composition comprises an aromatic
polycarbonate, a metal compound b) and ABS, the latter is added to reduce
the degradation of the aromatic polycarbonate in an aromatic
polycarbonate composition also containing a metal compound b).

[0045] The concentration of these components c) present in the composition
of the present invention is from 2.5 up to 50 mass %, preferably from 3
up to 50 mass %, more preferably from 3.5 up to 50 mass %, even more
preferably from 4 up to 50 mass % and even more preferably from 4.5 up to
50 mass %. A man skilled in the art can easily determine, in dependence
of the type of component c), the amount of component c) that should at
least be present in the polycarbonate composition containing component b)
for decreasing or preventing the degradation of the polycarbonate. The
concentration of these components c) present in a polycarbonate
composition rendered flame retardant by adding one or more, preferably
chlorine and bromine free and phosphate ester based, flame retarding
compounds is preferably from 2.5 up to 15 mass %, more preferably from
4.5 to 15 mass %. The concentration of these components c) present in a
polycarbonate composition that does not contain flame retarding compounds
is preferably from 15 up to 50 mass %, more preferably from 20 up to 50
mass % and even more preferably from 30 up to 50 mass %.

[0046] The polycarbonate composition according to the invention may
further contain d) from 0 to 25 mass % of one or more other additives,
wherein the sum of a) to d) is 100%. These include the customary
additives such as stabilizers against thermal or thermo-oxidative
degradation, stabilizers against hydrolytic degradation, stabilizers
against degradation from light, in particular UV light, and/or
photo-oxidative degradation, impact modifiers, processing aids such as
release agents and lubricants, colorants such as pigments and dyes,
fillers including minerals such as wollastonite or aluminium silicates,
or flame retardants. Suitable examples of such additives and their
customary amounts are stated in the aforementioned Kunststoff Handbuch,
3/1.

[0047] The polycarbonate composition according to the invention may
further contain an acid or an acid salt as additive d). In one
embodiment, the acid or acid salt is an inorganic acid or inorganic acid
salt. In one embodiment, the acid is an acid comprising a phosphorous
containing oxy-acid. In one embodiment, the phosphorous containing
oxy-acid is a multi-protic phosphorus containing oxy-acid having the
general formula HmPtO4, where m and n are each 2 or
greater and t is 1 or greater. Examples of such acids include, but are
not limited to, acids represented by the following formulas:
H3PO4, H3PO3, and H3PO2. In some
embodiments, the acid will include one of the following: phosphoric acid,
phosphorous acid, hypophosphorous acid, hypophosphoric acid, phosphinic
acid, phosphonic acid, metaphosphoric acid, hexametaphosphoric acid,
thiophosphoric acid, fluorophosphoric acid, difluorophosphoric acid,
fluorophosphorous acid, difluorophosphorous acid, fluorohypophosphorous
acid, or fluorohypophosphoric acid. Alternatively, acids and acid salts,
such as, for example, sulphuric acid, sulphites, mono zinc phosphate,
mono calcium phosphate, mono natrium phosphate, and the like, may be
used. It has been found that the presence of acid or acid salt may result
in a further decrease of the degradation of the aromatic polycarbonate in
an aromatic polycarbonate composition also containing a metal compound
b). It has been found that the presence of acid or acid salt is in
particular advantageous in case there is, despite the presence of
component c) in the polycarbonate composition, still substantial,
although reduced, degradation of the polycarbonate. In case the acid or
acid salt is present in the composition of the invention, the acid or
acid salt is preferably present in the composition in an amount of 0.01-1
mass %. A man skilled in the art will be able to find, in dependence of
the amounts and types of component c), the optimum amount of acid or acid
salt as is to be used for further reducing the degradation of the
polycarbonate. In one embodiment of the invention, the composition
comprises an aromatic polycarbonate, a metal compound b), MBS as
rubber-like polymer c) and an acid or acid salt, wherein MBS and the acid
or acid salt are added to reduce the degradation of the aromatic
polycarbonate in an aromatic polycarbonate composition also containing a
metal compound b).

[0048] Although a polycarbonate such as bisphenol-A polycarbonate in
itself has a fairly good flame retarding behaviour, a polycarbonate
composition is preferably rendered flame retardant by adding one or more
flame retarding compounds. Suitable examples of flame retarding compounds
are certain alkali or earth alkali sulphonates, sulphonamide salts,
perfluoroborates, halogenated compounds, especially bromated aromatic
compounds, and phosphorus-bearing organic compounds, especially phosphate
esters such as triphenyl phosphate. Suitable phosphorus-bearing compounds
are described in for example DE 19828535 A1 (Komponente E), in EP 0640655
A2 (Komponente D) and in EP 0363608 A1 (component C). As flame retarding
compound use is preferably made of at least an oligomer phosphate ester,
such as resorcinol diphenylphosphate (RDP), bisphenol-A diphenylphosphate
(BDP) or mixtures thereof. Such compositions exhibit an excellent
combination of mechanical, flame retarding and processing properties.
Additionally the composition often contains a fluoropolymer such as
polytetrafluoroethylene to enhance its dripping properties in a fire
test.

[0049] In a preferred embodiment, the composition of the present invention
further comprises a particulate additive, such as fillers. Typical
fillers are inorganic and/or organic particles, such as silicon dioxide
(natural, precipitated, or fumed), calcium carbonate, magnesium
carbonate, barium carbonate, calcium sulfate, barium sulfate, lithium
phosphate, calcium phosphate, magnesium phosphate, titanium dioxide
(rutile or anatase), kaolin (hydrated or calcined), aluminum oxide,
aluminum silicates, lithium fluoride, the calcium, barium, zinc, or
manganese salts of the dicarboxylic acids used, or crosslinked polymer
particles, e.g. polystyrene or polymethyl methacrylate particles. In a
more preferred embodiment of the present invention, the particulate
additive is titanium dioxide suited for the use in aromatic
polycarbonate. It has been found that the presence of such laser
absorbing additives results in that accumulation and/or adhesion of
metal, obtained by metallization of the irradiated areas of moulded parts
obtained from such a composition, can be increased.

[0050] The polymer composition may further comprise reinforcing agents,
such as glass fibres.

[0051] The components b), c) and optionally other additives as described
above, and also any other particulate additives and reinforcing agents
may be introduced into the aromatic polycarbonate by means of suitable
mixing devices such as single-screw or twin-screw extruders, preferably a
twin-screw extruder is used. Preferably, aromatic polycarbonate pellets
are introduced into the extruder together with at least components b) and
c) and extruded, then quenched in a water bath and then pelletized. The
invention therefore further relates to a process for producing an
aromatic polycarbonate composition according to the present invention by
melt mixing components a), b), c) and optionally other (particulate)
additives also any other particulate additives and reinforcing agents.

[0052] The invention further relates to moulded parts that contains the
polycarbonate composition according to the present invention. The
invention relates in particular to a moulded part produced by injection
moulding of the composition according to the invention. It has
surprisingly been found that moulded parts containing the polycarbonate
composition according to the present invention possess mechanical
properties that are on the same or almost on the same level as that of a
similar composition not containing component b); in particular strength
and rigidity, and toughness, in particular elongation at break,
resistance to crack formation following drop test and resistance to crack
formation as initiated by certain chemicals such as organic solvents
(i.e. environmental stress cracking resistance or ESCR). This is
especially advantageous for moulded parts that are a structural element
of a small but complex appliance such as a mobile telephone (GSM), a
personal digital assistant (PDA), and the like. The high toughness allows
high loading of screwed joints or `snap fit` joints between moulded
parts.

[0053] The invention accordingly also relates to an article, in particular
a circuit carrier, that contains a moulded part produced from the
composition according to the invention. In one embodiment, such a circuit
carrier is used for producing an antenna.

[0054] The invention further relates to a process for producing such a
circuit carrier which process comprises the steps of providing a moulded
part that contains the polycarbonate composition according to the present
invention, irradiating areas of said part on which conductive tracks are
to be formed with electromagnetic radiation to break down the metal
compound b) and releasing metal nuclei, and subsequently metallizing the
irradiated areas (by chemical reduction). In a preferred embodiment,
electromagnetic radiation is used to simultaneously release metal nuclei
and effect ablation of the part while forming an adhesion-promoting
surface. This provides a simple means to achieve excellent adhesive
strength of the deposited metallic conductor tracks. Advantageously, a
laser is used to produce the electromagnetic radiation to release the
metal nuclei. Thus, the electromagnetic radiation is preferably laser
radiation. The wavelength of the laser is advantageously 248 nm, 308 nm,
355 nm, 532 nm, 1064 nm or of even 10600 nm. The deposition of further
metal onto the metal nuclei generated by electromagnetic radiation
preferably takes place via electroplating (solution-chemistry) processes.
Said metallizing is preferably performed by immersing the moulded part in
at least one electroless plating bath to form electrically conductive
pathways on the irradiated areas of the moulded part.

[0055] The invention will now be elucidated with reference to the
following examples and comparative experiments.

COMPARATIVE EXPERIMENTS A-H AND EXAMPLES 1-8

[0056] The compositions of Comparative Experiments (CEx) A-H and of
Examples (Ex) 1-8 were prepared from the components as given in Table 1.

[0057] All samples were extruded on a co-rotating twin screw extruder at a
temperature of 280° C. according the compositions as given in
Table 2 to 5. The extrudate was granulated. Using the collected
granulate, MFI and MV (melt viscosity) was measured at 260° C./5
kg load (IS01133) and 260° C./1500 s-1 (determined in a
capillary rheograph using a capillary with a L/D ratio of 30 according to
ISO 11443), respectively for the PC-ABS compositions (Table 3) and at
300° C./1.2 kg load and 300° C./1500 s-1 for the other
compositions (Table 4 and 5). To illustrate any side effect of the
difference in temperature of the MFI and MV measurement, the PC-ABS
compositions using ABS1 (CEx C and Ex 1) were also measured at both
temperature settings (260° C. and 300° C.). Subsequently,
the granulate was injection moulded into Izod bars and plaques (70*50*2
mm) using a melt temperature of 260° C. for PC-ABS compositions
(Table 3) and using a melt temperature of 290° C. for the other
compositions (Table 5 and 5). Izod Notched impact strength was measured
according to ISO180/4A.

[0058] Plating performance was judged after laser activation on the
injection molded plaques and a subsequent plating procedure in an
electroless galvanic plating bath. Plating performance was judged
according to the thickness of the copper layer and the adhesion strength
of the metal layer onto the polymer substrate.

[0059] The level of degradation of polycarbonate was judged by comparison
of the flow (MFI and MV) and toughness properties (Izod Notched Impact)
of the samples with and without the copper chromite spinel. To illustrate
that this is in accordance with the molecular weight degradation, the
molecular weight of samples CEx A, CEx B and Ex 1 was also measured by
Gel Permeation Chromatography (GPC) in dichloromethane solvent. Linear
Polystyrene was used for calibration, so values reported are
Polycarbonate weight averaged molecular weight (Mw) relative to
Polystyrene.

[0060] Table 2 shows the compositions and results of Comparative
Experiment A and B. Comparing CEx A and CEx B shows that addition of the
copper chromite spinel to a polycarbonate composition results in a very
high increase of MFI and very high decrease of MV, indicating that
polycarbonate is degraded to a high extent, as is confirmed by the weight
average molecular weight (Mw) measured by GPC. This reduction of
molecular weight also results in a high decrease of the toughness (Izod
Notched Impact).

[0061] Table 3 and 4 show the compositions and results of Comparative
Experiment C to H and Example 1 to 6 of respectively the PC-ABS blends
and the other PC-rubber blends. Comparing the results of the Examples
with copper chromite spinel with the Comparative Experiments without the
copper chromite spinel shows that the presence of the copper chromite
spinel (CuCr2O4 powder) in a blend of polycarbonate with a
rubber-like polymer surprisingly results in that the MFI does not
increase at all or to a much lesser extent, the MV does not decrease at
all or to a much lesser extent and the toughness remains on the same
level or decreases to a much lesser extent as for Comparative Experiment
B (compared to CEx A). This indicates that the polycarbonate is degraded
to a much lesser extent when the copper chromite spinel is added to the
blends of Polycarbonate with a rubber-like polymer than when added to
polycarbonate alone (like in CEx B). This reduction in degradation is
also confirmed by the weight average molecular weight (Mw) result as
measured by GPC on Ex 1, which shows an almost similar value as the
reference CEx A.

[0062] Table 5 shows the compositions and results of Example 7 and 8,
which are blends similar to Example 4 and 6, but with the addition of
0.1% Mono Zinc Phosphate (MZP). It is shown that addition of an acid salt
like MZP can lead to a further stabilization (decrease in MFI and
increase in MV and toughness) for the blends that showed the largest
difference between the Comparative Experiments (CEx F and CEx H) and
their Examples (Ex 4 and Ex 6).